[nheft]

Our controller is en route to IFI as we speak. A swap was not possible; we're taking downtime and focusing on mechanical issues until we get our controller back.

Before sending it back I ran some more tests and made an interesting observation - I placed a light duty Pep Boys automotive switch in series with the HI-AMP circuit breaker and used the switch to turn the controller on and off. Still seeing intermittent failures but significantly less often than when powering up and down with the breaker. These observations were made with the 7.2 backup battery out of the equation. The only difference I can think of is the contact bounce characteristics of the switch versus the HI-AMP breaker. I looked at the turn-on transient of the breaker and the switch on a scope. They each exhibit about 5 ms of contact bounce before finally settling out to +12V. Tom at IFI thinks what I saw was coincidence. Wierd problem. Time will tell what the cause is.